Aeration apparatus for discharge control of particulate matter

ABSTRACT

The invention is directed to a method and apparatus for establishing and maintaining a uniform mass flow rate of particulate solids and gas mixture from a container to a receiving reactor. A preferred embodiment utilizes an aeration tube suspended in the particulate mixture which, in conjunction with a second independent aeration device, serves as a fluidic valve to maintain a uniform mass flow rate.

RELATED APPLICATIONS

This invention is related to Assignee's patent applications; S/N 355,860 filed May 18, 1989 and which is a continuation of S/N 098,161 (now abandoned); S/N 098,178 (now U.S. Pat. No. 4,853,003); and S/N 098,588 (now U.S. Pat. No. 4,830,545), all filed on Sept. 18, 1987; and to copending applications S/N 209,602, S/N 209,603 and S/N 209,605, all filed concurrently herewith.

BACKGROUND OF THE INVENTION

Conventional coal feed systems using gravity flow of solids, such as in a coal feed to coal-fired boilers, can tolerate major fluctuations in the coal mass flow rate and suspension density.

Various devices have been built for discharging substances which tend to flow easily by gravity, such as grain and coal. While devices such as those disclosed in U.S. Pat. Nos. 3,289,396, 3,367,724, 4,529,336, 3,424,352, and 4,067,623 are concerned with providing "efficient discharge" of particulate materials from bulk storage tanks and avoiding bridging and incomplete discharging from such tanks, these devices do not maintain a uniform mass flow rate of a particulate solids and gas mixture discharged in a uniform manner to a receiving reactor.

The present invention is directed to overcoming this problem in the art.

Applicants are not aware of any prior art which, in their judgment as persons skilled in this particular art, would anticipate or render obvious the present invention. However, for the purpose of fully developing the background of the invention, and establishing the state of requisite art, the following art, in addition to Assignee's above-identified related applications, is set forth: 4,482,275; 3,367,724; 4,067,623; 3,424,352; 4,529,336; Re 24,716 (2,794,686); 3,007,744; 2,568,379; 2,400,194; 2,115,023; 3,230,016; 3,285,739; 3,289,396; 4,381,924; 3,479,093; 3,121,593; 3,159,432; 2,499,766; 3,411,832; 3,720,351; 2,806,781; 3,822,919; 699,405; 3,994,702; 4,018,588; 3,001,829; 2,715,551; 2,631,759; Japanese patents 98,030; 102,431; and 107,316; "Monitor Aeration Devices", Monitor Manufacturing Company, Elburn, IL 60119.

SUMMARY OF THE INVENTION

The invention relates to a high pressure, reliable, dry coal feed system.

The primary purpose of the present invention relates to maintaining a uniform mass flow rate of a particulate solids and gas mixture discharged, under high temperature and pressure conditions, to a receiving reactor. In particular, this invention relates to pulverized coal discharged to a gasifier for the manufacture of synthesis gas.

Preferably, such an apparatus includes: means for introducing the mixture into a first containing means having converging walls, the containing means having at least one port formed at the apex thereof for discharging the mixture therefrom, means for selectively injecting gaseous fluid under pressure into the mixture, and means for discharging the particulate solids from the first containing means at a uniform mass flow rate.

Preferably, a method for controlling mass flow rate of solids to a reactor includes: introducing the mixture into a first containing means having converging walls, the containing means having at least one port formed at the apex thereof for discharging the mixture therefrom, selectively injecting gaseous fluid under pressure into the mixture, and discharging the particulate solids from the first containing means at a uniform mass flow rate.

The various features of novelty which characterize the invention are pointed out with particularity in the claims forming a part of this disclosure. For a better understanding of this invention, its operating advantages and specific objectives obtained by its uses, reference may be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a coal gasification system employing an embodiment of this invention.

FIG. 2 is a cross-section of the preferred embodiment taken along line 2--2 of FIG. 1.

FIG. 3 is an isometric view of the aerating means of the present invention.

DESCRIPTION OF A PREFERRED EMBODIMENT

Generation of synthesis gas occurs by partially combusting a carbonaceous fuel, such as coal, at relatively high temperatures in the range of 1000°-3000° C. and at a pressure range of from about 1-70 bar, in the presence of oxygen or oxygen-containing gases in a coal gasification reactor, hereinafter referred to as a gasifier. Steam, carbon monoxide, carbon dioxide and oxygen-containing gases including air, oxygen-enriched air, and oxygen are optionally diluted with nitrogen and/or other inert gases.

In the present invention, the fuel and gas mixture is discharged from a feed vessel apparatus, preferably having multiple outlets, each outlet being in communication with at least one burner associated with the gasifier. Typically, a gasifier will have burners in diametrically opposing positions, but this is not a requirement of this invention. Generally, the burners have their discharge ends positioned to introduce the resulting flame and the agent of combustion into the gasifier.

Of particular importance in the manufacture of synthesis gas is the uniform manner in which the particulate fuel is introduced to the burners within the gasifier. Fluctuations in the mass flow rate of coal being supplied to the burners of the gasifier are detrimental to the gasifier's performance. For example, such fluctuations can cause inefficient combustion of fuel within the gasifier and damaging heat fluxes to the burner face which could result in thermal stresses on the burner face. If the mass flow rate of the particulate fuel fluctuates, zones of underheating are generated next to zones of overheating in the gasifier. As a result, in the zones of underheating the fuel is not completely gasified and in zones of overheating the fuel is completely converted into less valuable products, viz. carbon dioxide and water vapor. Additionally, localized high temperatures in the gasifier could damage the refractory lining which is normally arranged at the inner surface of the gasifier wall.

Since the residence time of the coal within the reaction zone of the reactor is approximately 5 seconds or less, the coal mass flow rate should preferably be constant over periods of this order and preferably over shorter periods to maintain constant local conditions.

Various factors substantially affect the mass flow rate of the fuel being supplied to the burners. In particular, the discharging of the particulate fuel from a feed vessel apparatus and the transporting by conduit of the fuel from the vessel to the gasifier affect the mass flow rate of fuel to the gasifier. Specifically, fuel and gas mixtures having densities ranging from about 50-800 kg/m³ transported through a conduit having a diameter less than 150 mm or larger experience significant pressure drop due to the summation of various contributions such as frictional losses, restrictions, curvatures, etc., within the conduit.

The preferred embodiment of the invention utilizes a vessel having downwardly-converging walls at the lower end thereof, the vessel having at least one port at the apex and having an aerating means for aerating the solids within the converging walls of the vessel so as to maintain a uniform mass flow rate of the solids and gas mixture discharged to a gasifier. Gaseous fluids are injected into the aeration means at a selected pressure and rate to maintain a uniform mass flow rate of a particulate solids and gas mixture to be discharged to the receiving gasifier. Furthermore, use of the aerating means as a fluidic valve provides greater flexibility for operating the process under varying conditions, such as different coal types, coal moisture content, etc.

An advantage of the present invention is that maintaining a uniform mass flow rate of a particulate solids and gas mixture to a gasifier prevents the occurrence of zones of underheating and overheating within the gasifier.

A further advantage of the present invention is the protection afforded the refractory lining within the gasifier due to the prevention of zones of underheating and overheating.

An additional advantage of the present invention is more efficient utilization of fuel in the production of synthesis gas.

Another advantage of the present invention is the capability of maintaining high suspension densities, e.g., greater than 200 kg/m³, in the transport line from the vessel to the gasifier thereby reducing the consumption of aeration and pneumatic transport gas and avoiding dilution of the synthesis gas produced in the gasifier which would make the synthesis gas a less valuable product.

Although the invention is described hereinafter primarily with reference to pulverized coal, the method and apparatus according to the invention are also suitable for reactive solids and other finely divided solid fuels which could be partially combusted, such as lignite, anthracite, bituminous, brown coal, soot, petroleum coke, and the like. Preferably, the size of solid carbonaceous fuel is such that 90 percent by weight of the fuel has a particle size smaller than 100 mesh (A.S.T.M.). The invention is intended to accommodate mass flow rates in the range of 300-500,000 pounds per hour through 4-150 mm or larger pipes.

Additionally, the present invention can be used for both granular, pulverized, and powdered solids such as resins, catalysts, fly ash, bag house and electrostatic precipitator fines.

Having thus generally described the apparatus and method of the present invention, as well as its numerous advantages over the art, the following is a more detailed description thereof, given in accordance with specific reference to the drawings. However, the drawings are of a process flow type in which auxiliary equipment, such as pumps, compressors, cleaning devices, etc. are not shown. All values are merely exemplary or calculated.

Referring to FIG. 1, an apparatus for maintaining a uniform mass flow rate of a particulate solids and gas mixture discharged from a holding vessel apparatus, such as a feed hopper 11 operated at elevated pressures of 1-70 bar, via conduit 40 to a receiving reactor, such as a gasifier 9, generally includes means for introducing the mixture, such as an inlet port 10, into the feed hopper 11. The feed hopper 11 directs the material into generally cone-shaped receiving means shown generally at 7 and described more particularly with reference to FIG. 2.

Referring now to FIGS. 2 and 3, an aeration device shown generally at 6 is adapted for positioning in the receiving means 7 of the coal gasification system of FIG. 1. The aeration device 6 comprises a hollow shaft or tube (first aeration means 14) supporting a rigidly mounted mounting flange 16 at its upper end and a second aeration means 27 (which may also serve as a centering and supporting means) rigidly mounted approximately midway between its two ends. The mounting flange 16 has a plurality of holes 28 for mounting to the coal feed hopper 11. The mounting flange 16 is held in place on the aeration shaft 14 by means of gussets 29 which may be welded to the flange 16 and to the hollow shaft 14. A tube 32 extends from the periphery 33 of the flange 16 to the shaft 14 and communicates with the hollow interior thereof. The shaft 14 has a plurality of air-exit holes 34 at the lower end thereof for communication with the coal mixture traveling through the receiving means 7. A gaseous mixture from fluid source 20 is forced under pressure into the mouth 35 of tube 32. The gaseous fluid is controlled by flow controller 30 and measured by flowmeter 25. Since the top end 36 of the aeration tube 14 is closed, the gaseous fluid travels down the aeration tube 14 and exits through the holes 34 thereby aerating the coal mixture in the receiving means 7. A second aeration means 27, which may also serve as a centering and supporting means, may be welded to the tube 14 and supports a plurality of spacer blocks 37 at its periphery for centering the aeration device 6 in the receiving means 7. It is noted that aeration of the coal (solids) via the aeration tube 14 is not limited to the use of holes. Porous plugs may also be used or even an aeration tube made from sintermetal could serve in the same way. Aeration means 27 could likewise utilize porous plugs or be made from sintermetal. One skilled in the art will know that material selection is related to the process and mechanical requirements.

In a preferred embodiment, FIGS. 2 and 3, the second aeration means 27 may be a hollow, cone-shaped device whose upward sloping walls 41 are perforated but whose base 42 is solid. The angle of the cone should be less than or equal to 120°. Gaseous aeration fluids are directed into the interior of the cone 27 via the mouth 35a of a second tube 32a and exit through the perforations in the walls 41 thereby substantially reversing fluid flow and further aerating the mixture in the receiving means 7. Thus aeration cone 27 may be used as an independent means of aerating the particulate solids in the receiving means 7. Aeration fluid is supplied in a manner similar to, or the same as, aeration tube 14, i.e., a fluid source 20a controlled by flow controller 30a and measured by flowmeter 25a. The invention claimed herein serves to promote a regular flow into the section of the receiving means 7 below the aeration means 27. Aeration of the particulate solids serves to overcome interparticle friction and the frictional forces between receiving means 7 and the solids. Moreover, by changing the aeration rate the solids discharge can be changed, thereby serving a fluid valve control aspect. Aeration tube 32a may, in a preferred embodiment, be concentric with aeration tube 14 as shown in FIG. 2.

Although aeration means 14 and 27 are shown as being fixed, in some applications it may be desirable that they be movable as in Assignee's copending application S/N 209,605, which application is incorporated herein by reference.

The preferred embodiments, as described above, utilize the walls of the receiving means 7 to contain and direct the mixture through the discharge port 15 and into the transport line 40. It may be necessary, or preferable in some instances, to utilize the aeration means 14 and 27 in combination with a liner 8 within the receiving means 7 wherein the walls 12 of the liner 8 are completely permeable (as in Assignee's copending patent application S/N 355,860 filed May 8, 1989 and which is a continuation of S/N 098,161 filed Sept. 18, 1987, now abandoned) or wherein the walls 12 of the liner 8 use a plurality of porous plugs (as in Assignee's copending application S/N 209,605) which applications are incorporated herein by reference.

Referring now to FIG. 2, the receiving means 7 may be lined with a liner or inner shell 8 whose walls may be permeable, or porous, to gaseous fluids used for aerating the mixture. The liner 8 has converging walls 12 forming an included angle of less than about 150 degrees, preferably less than about 90 degrees, and converging toward at least one port 17 formed at the apex thereof for discharging the mixture therefrom.

The receiving means 7 comprises a jacket 13 which surrounds the liner 8 and is mounted to form a substantially enclosed space, or manifold, between the walls 12 of the liner 8 and the jacket 13. The jacket 13 has at least one outlet port 15 at the lower end thereof which is in axial alignment with the discharge port 17 of the liner 8 for discharging particles therefrom.

Means for isolating specific areas, preferably first and second areas 18, 19, respectively, located outside and circumferentially about substantially adjacent permeable portions of walls 12, such as a partition 22 within the substantially enclosed space between the jacket 13 and the walls 12, forms at least two substantially enclosed compartments. The jacket 13 includes means for selectively injecting gaseous fluid under pressure into tubes 32, 32a via inlet ports 35, 35a from pressurized fluid sources 20, 20a and into first and second areas 18, 19, such as via inlet ports 23, 23a, 23b, 23c from pressurized fluid source 21 (only one is shown for simplicity). Although fluid sources 20, 20a and 21 are preferably separate sources, it is recognized by those skilled in the art that gaseous fluid may be supplied from the same source.

The compartments formed within the substantially enclosed space between the walls 12 and the jacket 13 permit gaseous fluids, possibly having different densities, such as nitrogen or other inert gas and synthesis gas which is mainly carbon monoxide, hydrogen, and water, to be selectively injected into the compartments. The gas injected into the first area 18 may be more, equal, or less dense than the gas injected into second area 19. Preferably, the gas injected into area 18 would be inert and the gas injected into area 19 would be synthesis gas. The gas injected into area 18 would preferentially flow upwards and could be vented to control the pressure in the feed hopper 11 whereas the gas injected into area 19 flows preferentially downward and is transported to the gasifier 9.

The liner 8 is preferably made of a heavy, solid material such as stainless steel or alloy-20 and may be lined partially or completely with a porous material which may be metallic or nonmetalic, such as sintered powdered metal, woven stainless steel, or porous ceramic, depending upon the operating conditions and type of coal used in the process. The porous material has a selected permeability, preferably in the range of 0.1 to 10 acfm/ft² -psi. The porous material facilitates the uniform distribution of gaseous fluid injected from the pressurized sources into the liner 8 and prevents bridging of the particulate solids discharged from the liner 8 via discharge port 17.

The pore size of the porous material is based on, among other factors, the type of coal used. To allow greater operating flexibility to use various types of coal requiring differing pore sizes, the liner 8 is preferably interchangeable with another liner having porous material of a different permeability than the first liner 8.

Furthermore, introduction of the gaseous fluid into the pores of the porous material imparts a pressure restriction to the gaseous fluid thus ensuring an even flow distribution of the fluid throughout the porous material of the walls 12 of the liner 8. Similarly, the porous material serves to control the bulk density of the mixture within the liner 8 and the discharge rate of the mixture leaving the hopper 11 via port 15.

The flow rate and direction of the gaseous fluid, preferably nitrogen and synthesis gas, injected under pressure into aeration tubes 32 and 32a and into the first and second areas 18, 19, respectively, are controlled, by using flow controllers, 30, 30a, and 31, at a rate, measured by flowmeters 25, 25a and 26, sufficient to aerate the particulate solids in proximity to aeration means 14 and 27 and the porous material of walls 12, but at a rate below that which would fluidize the particulate solids located above the porous material. It is undesirable to inject the gases at a rate sufficient to fluidize the particles above the porous material, as is typically done in conventional systems, because it results in more inert gas diluting the synthesis gas produced in the gasifier 9 and thus yielding a less valuable product. The flow rate is such that a similar permeability as mentioned for the cone should be used to result in a uniform flow profile over the entire aeration device, e.g. 0.01 to 4 acfm/ft² -psi.

Aeration below the aeration means 27 serves as a diluting device to promote smooth and reliable flow through the cone outlet 17. It may also serve as a means to control the density of the coal in the feedline to the gasifier.

The slip velocity above the aeration cone 8, i.e., the relative superficial velocity between the gas and the coal within the hopper, should be less than 50% of the fluidization velocity and preferably near zero. Also, fluidization of the particles increases fluctuations of the mass flow rate of solids discharged from the coal feed hopper 11.

Additionally, the flow rates of the gaseous fluid from the fluid sources should not exceed the terminal falling velocity of the solids contained within the feed hopper 11. Terminal falling velocity is defined as the velocity at which the drag forces on a solid particle due to the flow of gases upward equals the downward force on the particle due to gravity. If the flow rates of the gases exceed the terminal falling velocity, then the solids will be discharged via the vent 50 rather than the discharge port 15.

Preferably, the flow rates of these gases from the sources 20, 20a and 21 are independently controllable by flow controllers 30, 30a and 31 and flow meters 25, 25a and 26 which permits the separate control of the amount of gas flowing upward and the amount of gas flowing downward relative to the flow of the coal. The aeration fluids used in first aeration means 14 may have a density equal to, less than or greater than the density of the fluid used in second aeration means 27.

For example, for a uniform mass flow rate of particulate solids and gas mixture of 2000 kg/hr having a suspension density of 450 kg/m³ discharged from the feed hopper 11, the rate of injecting nitrogen would be approximately 100 kg/hr. Should this rate be exceeded then the suspension density would be less than 450 kg/m³ and the synthesis gas produced in the gasifier 9 would be diluted by the nitrogen from the gas source. Additionally, should this rate be somewhat less than the selected rate, then the suspension density would be substantially higher than 450 kg/m³. Depending on the material and operating conditions, this situation could lead to less than stable flow.

Furthermore, the gaseous fluid may be injected in various directions and elevations to control the pressure and velocity profile which exists at the discharge port 15. Depending on the physical properties of the particles being transported, it may be necessary to have more than two compartments or to inject gas above the compartmented region.

This selective injection provides for separate control of the mixture density within the feed hopper 11 and the discharge density of the mixture leaving the hopper 11 via outlet port 15. As a result, the discharge port 15 of the hopper 11 is much smaller than conventional technologies for suspension densities of 200-500 kg/m³ preferred in the present invention.

The diameter of the discharge port 15 in the present invention is about 4 mm to about 150 mm for a solids and gas mixture having a suspension density of about 200-500 kg/m³. This diameter is larger than the maximum bridging diameter of the aerated particulate solids to prevent bridging of the solids as they exit the discharge port 17. The position of the rod end 38 and cone outlet port 17 is chosen such that no blockage of flow occurs. A typical value may be chosen so the clearance of port 17 should be at least the same as or larger than the clearance between the inner wall of the jacket and the rod. Conventional coal feed systems using gravity flow of solids assisted by aeration to break up bridging typically have a suspension density of less than 200 kg/m³ at the discharge outlet of the feed hopper and a corresponding feed vessel apparatus discharge port diameter of greater than about 150 mm. Diameters of the discharge port 17 greater than about 150 mm of a given mass flow rate used in the present invention are not desirable because either the velocity or suspension density would fall below the desired limits thus resulting in fluctuations of the mass flow rate of the coal and gas mixture to the gasifier 9.

Additionally, the smaller discharge port 17 diameter of the present invention, in conjunction with the compartmented injection of gaseous fluids, acts like a fluidic valve to control the particulate discharge rate and thereby eliminates the need for troublesome valves in transport hardware between the discharge of the hopper 11 and the gasifier 9.

Furthermore, the present invention may be provided with means for venting gas from the upper end of the hopper 11, say via port 50, for the purpose of maintaining an upward flow of gas through the solids in the feed hopper 11 of approximately 2 mm/sec and thereby eliminate local bridging of the solids and provide smoother flow to the discharge port 15.

The clearance comprising the annulus between aeration means 27 and the inner liner 8 of the converging jacket is important and should be selected to take into account solids properties (flow behavior) and wall material.

The foregoing description of the invention is merely intended to be explanatory thereof, and various changes in the details of the described method and apparatus may be within the scope of the appended claims without departing from the spirit of the invention. 

What is claimed is:
 1. An apparatus for maintaining a uniform mass flow rate of a particulate solids and gas mixture discharged from a holding vessel to a receiving reactor, said apparatus comprising:means for introducing said mixture into a containing means, said containing means being located within said holding vessel and having a downwardly converging wall which forms at least one port at the apex thereof for discharging said mixture therefrom; first tubular aeration means fixedly secured within said containing means and in axial alignment with said discharge port for aerating said mixture; second aeration means fixedly secured to said first aeration means for aerating said mixture in a direction opposed to that of said first aeration means; first and second gaseous fluid supplies for providing gaseous fluids to said first and second aeration means respectively; first and second means for selectively injecting said gaseous fluids under pressure into said first and second aeration means; means, in said first and second aeration means, for discharging said gaseous fluids into said particulate solids and gas mixture; and means for discharging said particulate solids from said first containing means.
 2. The apparatus of claim 1 wherein said means for discharging comprises selectively located holes.
 3. The apparatus of claim 1 wherein said means for discharging comprises selectively located porous material.
 4. The apparatus of claim 1 wherein at least a portion of said first aeration means is in close proximity to said discharge port thereby forming a fluidic value.
 5. The apparatus of claim 1 wherein said second aeration means is an upwardly extending hollow cone surrounding at least a portion of said first aeration means, the upwardly extending wall thereof being selectively perforated and wherein the interior of said hollow cone is in communication with said second gaseous fluid supply.
 6. The apparatus of claim 5 wherein said means for injecting said gaseous fluids includes:means for injecting said first gaseous fluid having a selected density into said first aeration means; and means for injecting said second gaseous fluid having a density greater than said first gaseous fluid into said second aeration means.
 7. The apparatus of claim 5 wherein said means for injecting gaseous fluids includes:means for injecting said first gaseous fluid having a selected density into said first aeration means; and means for injecting said second gaseous fluid having a density less than said first gaseous fluid into said second aeration means.
 8. The apparatus of claim 6 further comprising means for injecting said first gaseous fluid at a selected rate not to exceed the terminal falling velocity of the solids within said holding vessel apparatus.
 9. The apparatus of claim 6 further comprising means for injecting said second gaseous fluid at a selected rate not to exceed the terminal falling velocity of the solids within said holding vessel apparatus.
 10. The apparatus of claim 8 further comprising means for controlling the slip velocity of said gaseous fluid under pressure at a rate below a minimum fluidization velocity of said particulate solids within said holding vessel apparatus above said containing means.
 11. The apparatus of claim 5 further comprising jacket means for enclosing said downwardly converging wall of said containing means thereby forming a compartment therebetween, means for injecting a gaseous fluid into said compartment and wherein at least a portion of said wall of said containing means is porous to said gaseous fluids.
 12. The apparatus of claim 1 further comprising jacket means for enclosing said downwardly converging wall of said containing means thereby forming a compartment therebetween, means for injecting a gaseous fluid into said compartment and wherein at least a portion of said wall of said containing means is porous to said gaseous fluids.
 13. The apparatus of claim 12 further comprising means for dividing said compartment into a plurality of compartments. 